Circumferential flux electric machine with field weakening mechanisms and methods of use

ABSTRACT

There are presented various embodiments disclosed in this application, including methods and systems of arranging permanent magnets to switch from a first configuration designed for a first torque output to a second configuration designed for a second torque output.

RELATED APPLICATIONS

This application is a continuation of International Application No.PCT/US2016/057999, entitled “A Circumferential Flux Electric Machinewith Field Weakening Mechanisms and Methods of Use,” filed Oct. 20,2016, which claims the benefit of U.S. Provisional Application, Ser. No.62/244,155 entitled “A Switchable Toroidal Electric Motor/Generator”,filed on Oct. 20, 2015. The disclosures of which are incorporated byreference for all purposes.

This application is also commonly owned with the following U.S. patentapplications: U.S. provisional patent application Ser. No. 62/185,637entitled “A Improved Multi-Tunnel Electric Motor/Generator,” filed onJun. 28, 2015; U.S. provisional patent application Ser. No. 62/144,654entitled “A Multi-Tunnel Electric Motor/Generator,” filed on Apr. 4,2015; U.S. provisional patent application No. “62/055,615, entitled “AnImproved DC Electric Motor/Generator with Enhanced Permanent MagneticFlux Densities,” filed on Sep. 25, 2014; U.S. provisional patentapplication Ser. No. 62/056,389, entitled “An Improved DC ElectricMotor/Generator with Enhanced Permanent Magnetic Flux Densities,” filedon Sep. 26, 2014; U.S. application Ser. No. 13/848,048, entitled “AnImproved DC Electric Motor/Generator with Enhanced Permanent MagneticFlux Densities” filed on Mar. 20, 2013; which claims the benefit of U.S.Provisional Application Ser. No. 61/613,022, filed on Mar. 20, 2012, ofwhich all of the disclosures are hereby incorporated by reference forall purposes.

TECHNICAL FIELD

The invention relates in general to a new and improved electricmotor/generator, and in particular to an improved system and method forproducing rotary motion from a electro-magnetic motor or generatingelectrical power from a rotary motion input.

BACKGROUND INFORMATION

In many engines there is a need for a high torque output at relativelylow speeds or wattages, then as speeds increase, the torque can bedecreased. In electric vehicle applications, low speed operation oftenrequires constant torque operation at less than the base speed formoving heavy loads, or traversing rough terrain or inclines such ashills. For instance, high torque may be required for local trash pickupwhen the trucks are moving slowly from house to house, but there is lessneed for high torque when the truck is in on the highway at higherspeeds. Similarly, construction and tractors may have a need for hightorque during earth moving and plowing, but low torque when the machinesare in transport mode or moving along a street. Conveyor motors may needa high torque when they first start and lower torque after they havereached their operational speed.

In many cases, high speed operation requires double or triple the basespeed for cruising on level roads or developed industrial sites. In thishigh speed mode, torque requirements are low and constant poweroperation is desired. In constant power operation the available torqueis inversely proportional to the speed. Constant power mode in a motorequipped with a mechanism that controls back emf provides an operationthat is similar to shifting gear ratios in a transmission, i.e., higherspeeds are traded for lower available torque.

Thus, there is also a need for motors to generate high torque in onemode, and relatively lower torque in another mode once higher speedshave been reached. A motor that is able to shift from constant torquemode to constant power mode with speed extending beyond the base speedcan be utilized as a magnetic variable transmission. Conventionally,this may be accomplished through a transmission device. However,transmission devices result in inefficiencies and additional costs. Whatis needed is a motor that can switch between a high torque low speedconfiguration and a low torque high speed configuration.

SUMMARY

In response to these and other problems, there is presented variousembodiments disclosed in this application, including methods and systemsof arranging permanent magnets to switch from a first configurationdesigned for a first torque output to a second configuration designedfor a second torque output.

These and other features, and advantages, will be more clearlyunderstood from the following detailed description taken in conjunctionwith the accompanying drawings. It is important to note the drawings arenot intended to represent the only aspects of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of one embodiment of a motor/generatorcomponent according to certain aspects of the present disclosure.

FIG. 2A is a detailed isometric view of a magnetic disc assembly of themotor/generator component illustrated in FIG. 1.

FIG. 2B is a detailed isometric view of a magnetic disc assemblyillustrated in FIG. 2A with certain components removed for clarity.

FIGS. 3A through 3E are various detailed illustrations of a coilassembly and components of the coil assembly.

FIG. 4A is an isometric view of a magnetic toroidal cylinder or rotorassembly.

FIG. 4B is an exploded view of the magnetic toroidal cylinder of FIG. 4Aand various components of a back iron system.

FIG. 5A is a detailed perspective view illustrating one embodiment of amagnetic cylinder segment.

FIG. 5B is a detailed perspective view illustrating an alternativeembodiment of a magnetic cylinder segment.

FIG. 5C is a section view of a magnetic cylinder segment illustratingone arrangement of magnetic poles.

FIG. 5D is an exploded view of a toroidal magnetic cylinder illustratingthe magnetic pole arrangement of FIG. 5C.

FIG. 5E is an exploded view of the toroidal magnetic cylinderillustrating the magnetic pole arrangement of FIG. 5F.

FIG. 5F is a section view of a magnetic cylinder segment illustrating analternative arrangement of magnetic poles.

FIG. 5G is an exploded view of a magnetic cylinder illustrating themagnetic pole arrangement of FIG. 5H.

FIG. 5H is a section view of a magnetic cylinder segment illustrating analternative arrangement of magnetic poles.

FIG. 6 is a detailed isometric view of a magnetic cylinder segment withelectromagnetic forces imposed on the segment.

FIGS. 7A, 7B, and 7D are graphs illustrating the relative torque orback-emf voltages of the various magnetic pole arrangements of FIGS. 5Cto 5H.

FIG. 7C is a graph illustrating the relative torque between two magneticconfigurations.

FIGS. 8A to 8E are isometric views details of a rotation actuator whichmay be used with various embodiments of the present invention.

FIG. 9 is an exploded view illustrating an embodiment using twoactuators coupled to a magnetic disc assembly and slidingly coupled to arotor shaft.

FIG. 10 is a schematic illustration of a coil assembly coupled to acontroller.

DETAILED DESCRIPTION

Specific examples of components, signals, messages, protocols, andarrangements are described below to simplify the present disclosure.These are, of course, merely examples and are not intended to limit theinvention from that described in the claims. Well-known elements arepresented without detailed description in order not to obscure thepresent invention in unnecessary detail. For the most part, detailsunnecessary to obtain a complete understanding of the present inventionhave been omitted inasmuch as such details are within the skills ofpersons of ordinary skill in the relevant art. Details regardingconventional control circuitry, power supplies, or circuitry used topower certain components or elements described herein are omitted, assuch details are within the skills of persons of ordinary skill in therelevant art.

When directions, such as upper, lower, top, bottom, clockwise, orcounter-clockwise are discussed in this disclosure, such directions aremeant to only supply reference directions for the illustrated figuresand for orientation of components in the figures. The directions shouldnot be read to imply actual directions used in any resulting inventionor actual use. Under no circumstances, should such directions be read tolimit or impart any meaning into the claims.

FIG. 1 is an exploded perspective view of a motor/generator component100 illustrating a magnetic disc assembly 400, a rotor hub 300, and afirst actuating mechanism 600, which in certain embodiments, may beadapted to couple to one side of the magnetic disc assembly 400. Incertain embodiments, there may also be a second actuating mechanism 650adapted to couple to the opposing exterior side of the magnetic discassembly 400.

The magnetic disc assembly 400 comprises a back iron circuit 200 whichsurrounds and positions a toroidal magnetic cylinder 430 (not shown).The toroidal magnetic cylinder 430 surrounds a coil assembly 500 (notshown). As will be explained below, in certain embodiments, the rotorhub 300 supports various components of the back iron circuit 200 and iscoupled to a rotor shaft 302.

FIG. 2A is a detailed isometric view of the magnetic disc assembly 400.As illustrated in FIG. 2A, the back iron circuit 200 comprises theexterior of the magnetic disc assembly 400. In certain embodiments, theback iron circuit may be comprised of two portions. Relative to thepage, the back iron circuit may comprise a first or top portion 202 anda second or bottom portion 204. In certain embodiments, the firstportion 202 of the back iron circuit 200 comprises a first cylindricalwall 206 made of back iron material. For purposes of this applicationthe term “back iron” may refer to iron or a soft magnetic material, suchas any ferrous compound or alloy, any iron, nickel or cobalt alloy, orany laminated metal comprising laminated sheets of such material.

In certain embodiments, the first cylinder wall 206 may be coupled to aring or flat side wall 208 which is also made of back iron material. Aswill be explained below, in yet other embodiments, the first cylinderwall 206 may rotate through a predetermined angle with respect to theflat wall 208. In either case, the side wall 208 is adjacent to thefirst cylindrical wall 206.

The second portion of the back iron circuit 204 comprises a secondcylindrical wall 210, which in certain embodiments may be coupled to asecond ring or flat side wall 212. As will be explained below, in yetother embodiments, the outer cylinder wall 210 may rotate through apredetermined angle with respect to the flat wall 212.

In certain embodiments, a slot 214 may be defined between thecylindrical wall 206 and the flat side wall 208 to allow the passage ofcontrol wires and/or electrical conductors or adding mechanicalsecurement and support. In yet other embodiments, there may be a similarslot or gap defined between the cylindrical wall 206 and the cylindricalwall 210 (not shown in FIG. 2A).

FIG. 2B is a detailed isometric view of one embodiment of the magneticdisc assembly 400 with the back iron circuit removed for clarity. Asillustrated and as will be described below, the back iron circuitpositions and supports a toroidal magnetic cylinder 430 which surroundsthe coil assembly 500.

FIG. 3A is a detailed isometric view of one embodiment of the coilassembly 500 with the toroidal magnetic cylinder 430 removed forclarity. In certain embodiments, the coil assembly 500 may be a statorin that the coil assembly may be stationary. In yet other embodiments,the coil assembly 500 may act as a rotor because the coil assembly mayrotate. Furthermore, the embodiments illustrated depict only one way ofconfiguring and supporting the coil assembly 500. In other embodimentsthe coil assembly 500 may be supported by support ring extending througha center slot between the outer cylindrical walls 206 and 210 (FIG. 2A)from the coil assembly to an exterior casing or housing. In yet otherembodiments when the coil assembly 500 is functioning as a rotor, thecoil assembly may be supported by a support ring extending through acenter slot between the inner cylindrical walls 207 and 211 (FIG. 4B)from the coil assembly to the a shaft. The exact configuration dependson design choices as to whether the coil assembly is to be the stator orthe rotor.

Generally, as is typically used in the industry, a “rotor” may be thatportion or portions containing permanent magnets (regardless of whetherthe rotor is stationary or moving). In the illustrated embodiment, thecoil assembly 500 is a portion of a stator used in conjunction with arotor (or rotors) formed by the toroidal magnetic cylinder 430 (see FIG.2B).

FIG. 3B illustrates a coil assembly support 502 which comprises acylindrical or ring core 504 coupled to a plurality of teeth 506radially spaced about the ring core with respect to a longitudinal oraxial axis 401. For purposes of clarity, FIG. 3B shows a portion ofteeth 506 removed so that the ring core 504 is visible.

In certain embodiments, the ring core 504 may be made out of iron, softmagnetic materials, or back iron materials, so that it will act as amagnetic flux force concentrator. However, other core materials maybeused when design considerations such as mechanical strength, reductionof eddy currents, cooling channels, etc. are considered. As discussedabove, back iron materials may be iron, an iron alloy, laminated steeliron, or soft magnet materials. In some embodiments, the ring core 504may be hollow or have passages defined therein to allow liquid or aircooling.

One embodiment of an individual tooth 506 a and a small portion of thering core 504 are illustrated in FIG. 3C. The tooth 506 a may be madefrom a material similar to the material forming the core 504, forexample, iron, laminated steel or soft magnetic material. In theillustrated embodiment, each tooth 506 a extends from the ring core 504in radial (e.g., horizontal) and longitudinal (e.g., vertical)directions. Thus, each tooth 506 a comprises an outer portion 510extending radially away from the longitudinal axis 401 (FIG. 3B), aninner portion 512 extending radially toward the longitudinal axis 401, atop portion 514 extending in one longitudinal or axial direction, and abottom portion 516 extending in the opposing vertical or longitudinaldirection. The illustrated portion of the ring core 504 is coupled toand supports the individual tooth 506 a.

In certain embodiments, an exterior fin 520 couples to an exterior edgeof the outer vertical portion 510 and extends outward from the verticalportion 510 in opposing circumferential (or tangential) directions withrespect to the longitudinal axis 401. Similarly, an interior fin 522couples to an interior edge of the inner portion 512 and extends outwardfrom the portion 512 in opposing circumferential (or tangential)directions. As used in this disclosure, the term “circumferentialdirection” means the tangential or rotational direction about an axis,such as axis 401 (See FIG. 3B).

An alternative embodiment of an individual tooth 506′a and a smallportion of the ring core 504 are illustrated in FIG. 3D. The tooth 506′ais similar to the tooth 506 a described above in reference to FIG. 3Cexcept that the tooth 506′a also has horizontal or radial fins extendingfrom the top portion 514 and the lower portion 516. Specifically, afirst or top horizontal fin 518 extends in opposing horizontalcircumferential directions from an edge of the top horizontal portion514. Similarly, a second or bottom horizontal fin 519 extends inopposing horizontal circumferential directions from an edge of thebottom horizontal portion 516. In other words, the top horizontal fin518 joins the top portion of the exterior fin 520 to the top portion ofthe interior fin 522. Similarly, the bottom horizontal fin 519 joins alower portion of the exterior fin 520 to a lower portion of the interiorfin 522. From a structural perspective, the thickness of the fins 518and 519 maybe thicker closer to the joint with the respective horizontalmembers 514 and 516 and tapers as the fins extend away from the joints.

Adjacent teeth 506 or 506′ supported by the core ring 504 form radialslots 524 within the coil assembly support structure 502, as illustratedin FIG. 3A. FIG. 3E (which omits a portion of the teeth 506 for clarity)illustrates a plurality of individual coils or coil windings 526positioned radially about the ring core 504 and within the slots 524formed between the adjacent teeth 506 or 506′. In contrast, FIG. 3Aillustrates a complete coil assembly 500 showing all of the individualteeth 506 and individual coil windings 526 positioned within theindividual slots 524.

Each individual coil 526 in the coil assembly 500 may be made from aconductive material, such as copper (or a similar alloy) wire and may beconstructed using conventional winding techniques known in the art. Incertain embodiments, concentrated windings may be used. In certainembodiments, the individual coils 526 may be essentially cylindrical orrectangular in shape being wound around the ring core 504 having acenter opening sized to allow the individual coil 526 to be secured tothe core 504.

By positioning the individual coils 526 within the slots 524 defined bythe teeth 506 or 506′, the coils are surrounded by the more substantialheat sink capabilities of the teeth which, in certain embodiments, canincorporate cooling passages directly into the material forming theteeth. This allows much higher current densities than conventional motorgeometries. Additionally, positioning the plurality of coils 526 withinthe slots 524 and between teeth 506 reduces the air gap between thecoils. By reducing the air gap, the coil assembly 500 can contribute tothe overall torque produced by the motor or generator. In certainembodiments, the lateral fins 518 and 519 (FIG. 3D), the circumferentialfins 520 and 522 (FIGS. 3C or 3D) of the teeth 506 a or 506′a of thecoil assembly reduce the air gap between the structure of the coil toallow flux forces to flow from one fin to an adjacent fin when the coilsare energized and the coil assembly 500 begins to move relative to themagnetic tunnel.

The number of individual coils 526 can be any number that willphysically fit within the desired volume and of a conductor length andsize that produces the desired electrical or mechanical output as knownin the art. In yet other embodiments, the coils 526 may be essentiallyone continuous coil, similar to a Gramme Ring as is known in the art.

FIG. 4A illustrates one embodiment of the magnetic toroidal cylinder430. There is a top or first side or radial wall of magnets 402 (firstside wall 402) positioned about the longitudinal axis 401. Similarly,there is a bottom or second side or radial wall of magnets 404 (secondside wall 404) positioned longitudinally away from the first side wallof magnets 402. An outer cylindrical wall or longitudinal ring ofmagnets 406 is longitudinally positioned between the first side wall 402and the second radial wall of magnets 404. An inner cylindrical wall orlongitudinal ring of magnets 408 is also longitudinally positionedbetween the first side wall 402 and the second radial wall of magnets404 and laterally or radially positioned within the outer longitudinalring of magnets 406. When assembled, the magnets forming the radialwalls 402-404 and longitudinal walls 408-406 form the toroidal magneticcylinder 430, such as illustrated in FIG. 4A. Each wall or ring may bemade from a plurality of magnets. In industry parlance, each magneticwall of permanent magnets is called a “rotor.” Thus, a “four walled”magnetic toroidal cylinder may be known as a four rotor permanent magnetsystem.

In certain embodiments, the magnets forming the radial or side walls402-404 and longitudinal cylindrical walls 408-406 discussed herein maybe made of out any suitable magnetic material, such as: neodymium,Alnico alloys, ceramic permanent magnets, or electromagnets. The exactnumber of magnets or electromagnets will be dependent on the requiredmagnetic field strength or mechanical configuration. The illustratedembodiment is only one way of arranging the magnets, based on certaincommercially available magnets. Other arrangements are possible,especially if magnets are manufactured for this specific purpose.

In the illustrated embodiment of FIG. 4A, there may be slots between thewalls, such as slot 456 between the outer longitudinal wall 406 and thetop lateral or first side wall 402. As discussed above, in certainembodiments, there may also be slots within the walls, such as a slotwhich defined within the exterior cylindrical wall 406 (not shown). Theslots are designed to accommodate a support structure and/or wires andconductors. The term “closed magnetic tunnel” as used in this disclosurerefers to using a arrangement of the magnets forming the partialtoroidal magnetic cylinder 430 that that “forces” or “bends” the fluxforces from one side of the tunnel to the other (or in a circumferentialdirection) without first letting the magnetic forces escape through alarge slot. Thus, the slot widths may be limited to keep flux forcesfrom exiting through the slots. In other embodiments, additional magnetsmay be inserted into the slots to keep the flux forces channeled to apredetermined or a circumferential direction.

As discussed above, the magnets forming the toroidal magnetic cylinder430 are positioned and supported by the back iron circuit 200. FIG. 4Bis an exploded isometric view of the back iron circuit 200 and themagnets forming the toroidal magnetic cylinder 430. In this embodiment,the back iron circuit 200 comprises a first portion 202 and a secondportion 204. The first portion of the back iron circuit 200 comprisesthe side or top wall 208, a first circumferential outer wall or ring206, and a first interior wall or ring 207. The second portion 204 ofthe back iron circuit 200 comprises the side or bottom wall 212, thesecond circumferential outer wall or ring 210, and a second interiorwall or ring 211.

In this embodiment, each outer wall or ring 406 a and 406 b comprises aplurality of curved magnets. A plurality of inner longitudinal grooves240 a are defined and radially spaced around an inner surface 242 a ofthe first outer cylinder wall 206 of the back iron circuit 200. Theplurality of outer magnets forming the first portion 406 a of the outermagnetic wall 406 are sized to fit within the plurality of innerlongitudinal grooves 240 a. Similarly, a plurality of inner longitudinalgrooves 240 b are defined and radially spaced around an inner surface242 b of the second outer cylinder wall 210. The plurality of outermagnets forming the second portion 406 b of the outer magnetic wall 406are sized to fit within the plurality of inner longitudinal grooves 240b.

Each inner magnetic ring or wall portion 408a and 408b also comprises aplurality of curved magnets. A plurality of outer longitudinal grooves244 a are defined and radially spaced around an outer surface 246 a ofthe first inner cylinder wall 207 of the back iron circuit 200. Theplurality of inner magnets forming the first portion 408a of the innermagnetic wall 408 are sized to fit within the plurality of outerlongitudinal grooves 244 a. Similarly, a plurality of outer longitudinalgrooves 244 b are defined and radially spaced around an outer surface246 b of the second inner cylinder wall 211. The plurality of innermagnets forming the second portion 408b of the inner magnetic wall 408are sized to fit within the plurality of outer longitudinal grooves 244b.

Thus, the plurality of grooves 240 a, 240 b, 244 a and 244 b aredesigned to position and structurally support the plurality of magnetsforming the outer cylindrical magnetic wall 406 and the innercylindrical magnetic wall 408. Similarly, radial grooves 248 may bedefined in an interior facing surface of the flat side walls 208 and 212of the back iron circuit 200. The radial grooves 248 are also sized toaccommodate and support the ring of radial magnets 404 (and radialmagnets 402). In certain embodiments, adhesive materials known in theart may be used to fixedly couple the magnets forming the toroidalmagnetic cylinder 430 to the various elements of the back iron circuit200.

The embodiment illustrated in FIG. 4B uses two outer cylindrical walls206 and 210. In other embodiments, the two outer cylindrical walls 206and 210 may be replaced by a single cylindrical wall (not shown).Similarly, two inner cylindrical walls 207 and 211 are illustrated inFIG. 4 b. However, in certain embodiments, the inner cylindrical walls207 and 211 may be replaced by a single cylindrical inner wall (notshown).

In certain embodiments, the toroidal magnetic cylinder 430 may bedivided into a plurality of radial segments; or as known in the art:“poles.” For purposes of illustration, the toroidal magnetic cylinder430 is divided into eight (8) radial segments, where adjacent segmentshave alternating magnetic polarity orientations. However, any number ofradial segments may be used depending on specific design requirementsfor the motor or generator.

One such radial segment 440 is illustrated in FIG. 5A. Each radialsegment has an interior wall 408, an exterior wall 406, a top or firstside wall 402, and lower or second side wall 404. As illustrated in FIG.5A and discussed above in reference to FIG. 4B, the walls 406 and 408 myfurther be divided into two or more axial or longitudinal portions. Forinstance, the outer wall 406 in FIG. 5A comprises a first portion orwall 406 a and a second portion or wall 406 b. Similarly, the inner wall408 comprises a first portion or wall 408 a and a second portion or wall408 b.

In contrast, the radial segment 440′ of FIG. 5B illustrates anembodiment having a single magnetic exterior wall 406 and a singlemagnetic exterior wall 408. From an electrical-magnetic perspective, itmakes little difference whether the axial walls 406 and 408 of theradial segment 440 are formed from a single curved magnet as illustratedin FIG. 5B or two or more curved magnets as illustrated in FIG. 5A.However, in certain embodiments, it may be more convenient from amechanical perspective to use the radial segment 440 as illustrated inFIG. 5A or the radial segment 440′ as illustrated in FIG. 5B.

The NNNN Magnetic Pole Configuration:

The individual magnets forming the magnetic walls of the radial segment440 have their poles facing predetermined directions which affect theoverall performance of the magnetic cylinder 400. To illustrate, FIG. 5Cis a conceptual section view of the magnetic walls of radial segment440′ showing the magnetic pole orientation of the magnets forming thevarious walls of the radial segment. For instance, in FIG. 5C, themagnetic poles of the magnets forming the outer cylindrical wall 406 andthe inner cylindrical wall 408 have their magnetic poles orientatedalong a radial direction with respect to the longitudinal axis 401 (FIG.4A). In the illustration of FIG. 5C, the north magnetic poles of thecylindrical walls 406 and 408 point towards the interior 442 of theradial segment 440. Consequently, the south poles of the cylindricalwalls 406 and 408 point away from the interior 442 of the radial segment440. Similarly, the magnets forming the side walls 402 and 404 havingtheir magnetic poles orientated along the longitudinal or axialdirection such that their north poles also face towards the interior 442of the radial segment 440. For purposes of this disclosure, the magneticconfiguration illustrated in FIG. 5C may be thought of as a NNNNconfiguration because all of the poles pointing towards the interior 442of the radial segment have a north magnetic polarity.

In certain embodiments, an adjacent radial segment has its magneticpoles orientated in an opposite direction or orientation to that of theradial segment 440. In other words, in the adjacent segment, themagnetic poles of the magnets forming the outer cylindrical wall 406 andthe inner cylindrical wall 408 have their magnetic poles orientatedalong a radial direction pointing towards the longitudinal axis 401(FIG. 4A) such that their south magnetic poles point towards theinterior 442 of the radial segment 440. Similarly, the magnets formingthe side walls 402 and 404 have their magnetic poles orientated alongthe axial or longitudinal direction such that their south poles alsoface towards the interior of the radial segment 440. Thus, an adjacentradial segment may have a SSSS magnetic pole configuration because allinterior facing poles are of a south pole magnetic polarity.

The nomenclature of NNNN or SSSS is meant to indicate that all interiorfacing magnets have the same polarity. This nomenclature should not betaken to limit the claimed invention to four walls forming the magneticsegment. Although the example embodiment illustrates a four sidedtoroidal cylinder 430 where a cross section has four walls, it is withinthe scope of this invention to use three, five, six or even more wallsegments to form a toroidal magnetic cylinder or similar shape.

The radial segments forming the toroidal magnetic cylinder 430 alternatetheir magnetic pole orientation with each adjacent segment around thecylinder as illustrated in FIG. 5D. FIG. 5D is an exploded isometricview of the toroidal magnetic cylinder 430 showing the top ring or sidewall 402 and the outer cylindrical wall 406 pulled away from the lowerside wall 404 and inner cylindrical wall 408 so that the reader canvisualize the magnetic pole orientation of the eight radial segments 440forming this embodiment of the toroidal magnetic cylinder 430.

For example, the single radial segment 440′ as illustrated in FIG. 5Cmay be formed by a top wall segment 462, a lower wall segment 464, anouter wall 466, and a lower wall 468 on FIG. 5D which are radially andaxially aligned to form one segment (as illustrated in FIG. 6). Forpurposes of this disclosure, an “N” or a “S” is indicated on the face ofthe magnets to show the orientation of the magnetic poles of anyparticular wall a radial segment. As indicated by FIG. 5D, the“interior” side of the interior cylindrical wall 468 has an “N” definedthereon to indicate that the north pole of magnet or magnets formingthat wall are facing the interior of the tunnel (and towards theviewer). The lower wall portion 464 also has an “N” defined thereon toindicate that the north pole is facing upwards towards the interior ofthe toroidal magnetic cylinder 430. In contrast, the upper side wallportion 462 has an “S” defined thereon to indicate that the south poleof the magnetic ring is facing the viewer—which also indicates that itsnorth pole is facing away from the viewer and downwards toward theinterior of the toroidal cylinder as illustrated in FIG. 5C. Similarly,the outer wall portion 466 has an “S” defined thereon to indicate thatthe south pole of the magnetic wall is facing the viewer—which alsoindicates that its north pole is facing away from the viewer towards theinterior of the tunnel.

Thus, if a section was cut through the radial segment 440′, the magneticpole orientation of that particular radial segment would have all northpoles (i.e., an NNNN magnetic pole configuration) facing towards theinterior of the segment as illustrated in FIG. 5C. In contrast, theradial segments immediately adjacent to the radial segments 440′ wouldhave all of their south poles facing towards the interior of the segment(i.e., a SSSS magnetic pole configuration).

As will be explained below, the configuration of the toroidal magneticcylinder 430 indicated by FIG. 5C and FIG. 5D is a first configuration(or NNNN magnetic pole configuration) which produces a relatively hightorque when the toroidal magnetic cylinder 430 is used as part of themotor or generator.

The NSNS Magnetic Pole Configuration:

As described above, the magnets forming the toroidal magnetic cylinder430 are positioned and supported by various components of the back ironcircuit 200. Referring back to FIG. 4B, the upper side wall 208 of theback iron circuit 200 positions the magnets forming the magnetic wall402. The lower side wall 212 positions the magnets forming the magneticwall 404. The outer cylindrical walls 206 and 210 position the magnetsforming the exterior magnetic wall 406. The interior cylindrical walls207 and 211 positions the magnets forming the interior magnetic wall408. So, when the first rotation actuator 600 (FIG. 1) rotates the upperside wall 208 and the second rotation actuator 650 (FIG. 1) rotates thelower side wall 212 in unison about the axis 401 with respect to thelower be the outer cylindrical walls 206 and 210 and the interiorcylindrical walls 207 and 211, the plurality of magnets forming theupper magnetic side wall 402 and the lower magnetic side wall 404 willalso be rotated. (Most likely, in such an embodiment, an outercylindrical wall would replace both the outer cylindrical walls 206 and210 of FIG. 4B or the outer cylindrical walls 206 and 210 would bejoined to form one wall. Similarly, an interior cylindrical wall wouldreplace both the interior cylindrical walls 207 and 211 of FIG. 4B).

As previously noted, in the example embodiment illustrated in thefigures, there are eight radial magnetic segments 440 forming thetoroidal magnetic cylinder 430—meaning the angular distance between thecenters of the magnetic segments is 45 degrees. So, in the illustrativeembodiment, if the upper side wall 208 and the lower side wall 212 arerotated 45 degrees with respect to the outer cylindrical walls 206 and210 and the inner cylindrical walls 207 and 211, the magnetic side walls402 and 404 would follow and also be rotated 45 degrees with respect tothe magnets forming the inner and outer magnetic walls 408 and 406.

FIG. 5E is an exploded detailed isometric view of the toroidal magneticcylinder 430 where the magnets forming the upper and lower side walls402 and 404 have been rotated 45 degrees about the longitudinal axis 401with respect to the magnets forming the inner and outer cylindricalwalls 406 and 408 into a second magnetic configuration. FIG. 5F is asection view of the radial segment 440 after the rotation which showsthe radial segment in a second configuration or “NSNS” magnetic poleconfiguration.

In FIG. 5F, the magnetic poles of the magnets forming the outercylindrical wall 406 and the inner cylindrical wall 408 now have theirmagnetic poles orientated such that their south magnetic poles pointtowards the interior 442 of the radial segment 440. In contrast, themagnetic poles of the magnets forming the first side wall 402 and thelower side wall 404 have their magnetic poles orientated such that theirnorth magnetic poles point towards the interior 442 of the radialsegment 440. Thus, the second configuration is a NSNS magnetic poleconfiguration because adjacent magnetic interior faces alternate betweenhaving their south poles pointing towards the interior and their northpoles pointing towards the interior. As indicated in FIG. 5E, adjacentradial segments would have the opposite magnetic pole orientation to theorientation illustrated in FIG. 5F.

As discussed below, once the rotation actuators 600 and 650 rotate themagnetic toroidal cylinder 430 into an NSNS magnetic orientation (asindicated by FIGS. 5E and FIG. 5F) the magnetic toroidal cylinder 430produces a lower torque than the first or NNNN magnetic configurationdiscussed above in reference to FIGS. 5D and 5C.

The NNSS Magnetic Configuration:

Referring back to FIG. 4B, if the upper side wall 208 and thecylindrical walls 206 and 210 were to be rotated in unison with respectto the lower side wall 212 and the interior cylindrical walls 207 and211, they would necessary rotate the upper side magnetic wall 402 andouter magnetic cylindrical wall 406 with respect to the lower sidemagnetic wall 404 and the inner magnetic cylindrical wall 408.

In such an embodiment, the rotation actuator 600 may be coupled to theupper side wall 208 and the upper side wall may be coupled to the outercylindrical wall 206. (Most likely, in such an embodiment, an outercylindrical wall would replace both the outer cylindrical walls 206 and210 of FIG. 4B or the outer cylindrical walls 206 and 210 would bejoined to form one wall. Similarly, an interior cylindrical wall wouldreplace both the interior cylindrical walls 207 and 211 of FIG. 4B.) Asthe rotation actuator 600 rotates, the rotation actuator will then movethe upper side wall 208, which in turn, causes the outer cylindricalwall 206/210 to move with respect to the inner cylindrical wall 207/211and the lower side wall 212. Alternatively, the rotation actuator 600may be coupled to the lower side wall 212 to produce relative rotationbetween the lower side wall and inner cylindrical wall 207/211 and theupper side wall 208 and the outer cylindrical wall 206/210. Regardlessof the placement of the rotation actuator, the effect is the same as therelative rotation produces a change in magnetic pole configuration. Theresulting orientation is illustrated in FIG. 5G.

FIG. 5G is an exploded detailed isometric view of the toroidal magneticcylinder 430 illustrating an additional magnetic pole configuration fromthe magnetic pole configuration illustrated in FIG. 5D. FIG. 5H is asection through the cylindrical segment 440′ showing this secondmagnetic pole configuration where the magnetic poles of the magnetsforming the outer cylindrical wall 406 and the top axial wall ring 402now have their magnetic poles orientated such that their south magneticpoles point towards the interior 442 of the radial segment 440. Incontrast, the magnetic poles of the magnets forming the inner cylinderwall 408 and the lower side wall 404 have their magnetic polesorientated such that their north magnetic poles pointing towards theinterior 442 of the radial segment 440. Thus, this third magneticconfiguration is a SSNN magnetic pole configuration because two adjacentmagnetic faces have their south poles pointing towards the interior andtwo adjacent magnetic faces have their north poles pointing towards theinterior.

As will be explained below, the third configuration or SSNN of thetoroidal magnetic cylinder 430 indicated by FIGS. 5G and FIG. 5Hproduces a lower torque than the NNNN magnetic configuration.

Comparison between Magnetic Configuration Types:

Turning now to FIG. 6, there is illustrated the magnetic cylindersegment 440 with a NNNN magnetic configuration. In other words, allmagnets forming the walls of the magnetic cylinder segment 440 (top sidewall 402, outer cylindrical wall 406, lower side wall 404, and innercylindrical wall 408) have their north poles facing inwards towards theinterior of magnetic cylinder segment. As is well known, the northmagnetic poles will generate a magnetic flux. The direction of themagnetic flux at the interior surface of the magnets is represented bythe arrows 490 a, 490 b, 490 c and 490 d all of which point to theinterior of the segment 440.

A portion of the coil assembly 500 is also positioned within theinterior of the magnetic cylinder segment (the rest of the coil assembly500 has been removed for clarity). The coil assembly 500 supports anindividual coil winding 526 as discussed above. In motor mode, a currentis introduced into the coil winding 526. The current circulates and willtake axial and radial directions as it rotates around the coil 526. Thedirection of the current is represented by arrows 530 a-530 d. As iswell known, when a current flows in the presence of a magnetic field, aLaplace or Lorentz force may be created. According to the left handrule, the force is perpendicular to the surface formed by the currentand magnetic field. Since the magnetic fields generated by the permanentmagnets also take radial and axial directions, the resulting force isexpected to be in tangential direction (tangential axis is perpendicularto the surface formed by the radial and axial vectors).

For an NNNN magnetic configuration, the Lorentz force may be representedby the arrows 540 a, 540 b, 540 c, and 540 d. In other words, as currentflows around each “leg” of the coil 526 in a magnetic field causes aLaplace or Lorentz force for that leg.

Effects of saturation and slots of the coil assembly can alter the exactforce calculation, but a relative measurement of force (and theresulting torque) can be determined.

For instance, in an NNNN magnetic configuration, the total Lorentz force(“F”) acting on the coil may be estimated by the following formula:

F=J×B

F=L{right arrow over (a)} _(z) ×B.{right arrow over (a)} _(r) .l ₁+I.{right arrow over (a)} _(r) ×−B.{right arrow over (a)} _(z) .l₂+(−I.{right arrow over (a)} _(z))×(−B.{right arrow over (a)}_(r).) l₁+(−I.{right arrow over (a)} _(r))×(B.{right arrow over (a)} _(z)).l ₂

F=2(IB)(l ₂ +l ₁){right arrow over (a)} _(ϕ)  (1)

Where:

-   -   I—is the current flowing through the coil 526    -   B—is the strength of the magnetic field acting on the current    -   a—represents a hybridization factor and relates to the Laplace        force and back emf    -   a_(z)—is the hybridization factor in the axial or longitudinal        direction    -   a_(r)—is the hybridization factor in the radial direction    -   a_(ϕ)—is the hybridization factor in the radial direction    -   I₁ is the width of the coil relative to the rotation axis (e.g.        the vertical length of the coil 526 of FIG. 6)    -   I₂ is the depth of the coil relative to the rotational axis        (e.g. the horizontal length of the coil 526 of FIG. 6).

In the above equations, every side or leg of the coil 526 contributeseither negatively or positively and the torque contribution of each legvaries as a function of radius and a function of geometry. Thus, eachcoil leg has an additive or subtractive effect depending on magnetgeometry and orientation.

In contrast to the NNNN magnetic configuration, the total average forcefor the NSNS magnetic configuration may be expressed as follows:

F=J×B

F=I.{right arrow over (a)} _(z) ×B.{right arrow over (a)} _(r) .l ₁+I.{right arrow over (a)} _(r) ×B.{right arrow over (a)} _(z) .l₂+(−I.{right arrow over (a)} _(z))×(−B.{right arrow over (a)} _(r)).l₁+(−I.{right arrow over (a)} _(r))×(−B.a{right arrow over (a)} _(z)).l ₂

F=2(IB)(l ₂ −l ₁){right arrow over (a)} _(ϕ)  (2)

As can be observed, the force from equation (1) above is greater thanthe force from equation (2) which indicates the total force generated bythe NNNN magnetic orientation is greater than the total force generatedby the NSNS configuration—all else being equal. Because the magneticcylinder segment 440 rotates about the longitudinal axis 401, theelectromagnetic torque generated by a NNNN magnetic configuration isalso greater than the electromagnetic torque generated by the NSNSmagnetic configuration.

Finite Element Modeling can be performed on a radial segment to verifythe above analysis. As is well known, a back electromotive force orback-EMF relates to the electromagnetic torque. Through finite elementmodeling, a graph of the back emf over time for the radial segment 440having a NNNN magnetic configuration and running at 3000rpm can begenerated. The results are illustrated as FIG. 7A which illustrate theback EMF voltage from a DC current with a soft magnetic composite statorcore (e.g. core 504) and a single turn (e.g. a single conductor) for thecoil. A similar analysis may be performed for the radial segment 440having a NSNS configuration. These results are illustrated as FIG. 7Bwhich illustrates the back EMF voltage from a DC current with a softmagnetic composite stator core and a single turn for the coil.

As illustrated, the electromagnetic torque generated in a NNNN magneticconfiguration is relatively greater than the torque generated in a NSNSconfiguration. In the absence of magnetic saturation, the ratio of thetorques developed by the two magnetic configurations (under identicalstator excitation) can be approximated as a function of coil dimensionsgiven below and graphically shown as FIG. 7C:

$\begin{matrix}{\frac{T_{A}}{T_{C}} = {\frac{l_{1} - l_{2}}{l_{1} + l_{2}} = \frac{1 - \left( \frac{l_{2}}{l_{1}} \right)}{1 + \left( \frac{l_{2}}{l_{1}} \right)}}} & (3)\end{matrix}$

where:

T_(A) is the torque from a radial segment having a NNNN magnetic poleconfiguration;

T_(C) is the torque from a radial segment having a NSNS magnetic poleconfiguration.

Notably the induced back-emf in these topologies follow the same trendand with a judicious selection of coil dimensions, one can introduce asignificant drop in the induced voltage for NNNN configuration whichcorresponds to a drop of electromagnetic torque of the same scale.

A similar analysis may be performed on the magnetic segment 440 having aNNSS magnetic configuration. Again, the total force generated fromLorentz force in each coil leg can be approximated as follows:

F=J×B

F=I.{right arrow over (a)} _(z) ×B.{right arrow over (a)} _(r) .l ₁+I.{right arrow over (a)} _(r)×(−B.{right arrow over (a)} _(z)).l₂+(−I.{right arrow over (a)} _(z))×(−B.{right arrow over (a)} _(r)).l₁+(−I.{right arrow over (a)} _(r))×(−B.a{right arrow over (a)} _(z)).l ₂

F=0·{right arrow over (a)} _(ϕ)

As can be observed, the force calculated from equation (1) above isgreater than force calculated from equation (4) which indicates thetotal force generated by the NNNN magnetic orientation is greater thanthe total force generated by the NNSS configuration—all else beingequal. Because the magnetic cylinder segment 440 rotates about thelongitudinal axis 401, the electromagnetic torque generated by a NNNNmagnetic configuration is also greater than the electromagnetic torquegenerated by the NSNS magnetic configuration.

Again, Finite Element Modeling can be performed on a radial segmenthaving an NNSS magnetic pole configuration to verify the above analysis.Through finite element modeling, a graph of the back emf over time forthe radial segment 440 having a NNSS magnetic configuration and runningat 3000 rpm can be generated. The results are illustrated as FIG. 7Dwhich shows the induced back-emf voltage using a soft magnetic compositecore and a single number of turns (e.g., a single conductor) for thecoil. As illustrated, the electromagnetic torque generated in a NNNNmagnetic configuration is relatively more than the torque generated in aNNSS configuration.

Field Weakening:

As demonstrated above, a NNNN magnetic configuration produces a greatertorque than either a NNSS or NSNS magnetic configuration. Consequently,the magnetic field produced by either the NNSS or the NSNS magneticconfiguration is less than the magnetic field produced by a NNNNmagnetic configuration under the same conditions. Thus, by graduallytransitioning from a NNNN magnetic configuration to either a NNSS orNSNS magnetic configuration, field weakening occurs. As the fieldweakens, the torque is lowered. As the torque is lowered, the rotationalspeed of the motor increases.

In certain embodiments, a motor at high torque may be in a constanttorque mode which results in a base speed. Above the base speed, and upto the motor maximum speed, the motor operates in a constant power mode.In a constant power mode, as the torque is lowered, current increases -resulting in a speed increase.

For instance, for a NNNN to NSNS transition, if the outer and innermagnetic cylinders 406 and 408 rotate with respect to the side magneticwalls 402 and 404, this rotation angle may be used as a controlledvariable and the following expressions may be used to demonstrate fieldweakening:

T ∝ BIl₁(1 + (1 − 2α)(l₂/l₁)) E = Bl₁(1 + (1 − 2α)(l₂/l₁))${\alpha = \frac{2P\; \delta^{0}}{360^{0}}};{\delta = {Rotation}};{{2P} = {{Pole}\mspace{14mu} {number}}}$

Thus, a transition from a NNNN magnetic configuration to a NSNS magneticconfiguration can effectively weaken the field without injection ofnegative d-axis current as typically used in the prior art and hencemaintain high efficiency in the constant power region. It is alsonotable that torque and speed may have identical decreasing andincreasing trends which may result in constant power.

FIG. 8A illustrates one embodiment of a rotation actuator. In theillustrative embodiment, a ball and knuckle assembly 602 is designed toconvert a longitudinal force into a rotational force which can thusrotate a shift plate or portions of the back iron assembly 200. Asexplained above, once the back iron assembly 200 rotates, the magneticwalls or rotors of the magnetic toroidal cylinder 430 also rotate withrespect to each other resulting in a change of magnetic poleconfiguration.

A shaft collar 604 may be sized to slidingly couple to the shaft 302 ofthe rotor hub 300 (FIG. 1) so that the shaft can freely rotate when theshaft is inserted into the shaft collar 604. In certain embodiments, theshaft collar 604 couples to a control lever (not shown) which applies alongitudinal force on to the shaft collar. In certain embodiments, theshaft collar 604 can couple to a longitudinal biasing mechanism (notshown) to retain the shaft mechanism longitudinally. Once the appliedlongitudinal force is great enough to overcome the biasing mechanism,the shaft collar moves longitudinally towards the magnetic disc assembly400 (FIG. 1). As the shaft collar 604 moves longitudinally, the shaftcollar exerts a longitudinal force on a stationary swash ring 606. Thestationary swash ring 606 is coupled to four ball joints 608 a-608 dextending laterally outward from the body of the swash ring.

In the illustrative embodiment, ends of four linkage rods 610 a-610 dcouple to ball joints 608 a-608 d. The opposing ends of the four linkagerods 610 a-610 d couple to a second set of ball joints 612 a-612 d. Theball joints 612 a-612 d are coupled to a rotating swash plate 616 viarotatable pin connections 614 a-614 d.

When a longitudinal force (e.g. downward force relative to the page) isapplied to the stationary swash ring 606, the swash ring 606 imparts aforce on the linkage rods 610 a-610 d. The longitudinal force on thelinkage rods cause the opposing ends of the linkage rods to rotate,which in turn will cause the ball joints 612 a-612 d and the rotatablepins 614 a-614 b to rotate. The rotation of the ball joints 612 a-612 dand the rotatable pin connections 614 a-614 d cause the swash plate 616to rotate as illustrated in FIG. 8B.

FIG. 8B illustrates the ball and knuckle assembly in a second or rotatedposition. Pins 618 coupled to the swash plate 616 couple to additionalswitch plates or to the components of the back iron circuit.

FIG. 8C illustrates the ball and knuckle assembly 602 coupled to a backiron component, specifically the flat side wall 212 (See FIG. 4B) andslidingly coupled to the rotor shaft 302. In the embodiment illustratedin FIG. 8C, the side wall 212 may be rigidly coupled to the interiorcylindrical wall 211. In this embodiment, the interior cylindrical wall211 may be rigidly coupled to the interior cylindrical wall 207 to actas one wall. In other embodiments, the interior cylindrical walls 207and 211 may be replaced by a single wall. In either event, when the sidewall 212 rotates, the inner cylinder walls 211 and 207 (or wall) rotatein unison with the rotation of the side wall 212.

The embodiment illustrated in FIG. 8C illustrates a NNNN configurationto NNSS configuration rotation. Refer back to FIGS. 5C and 5D for adiscussion of the NNNN configuration and to FIGS. 5G and FIG. 5H for adiscussion of the NNSS configuration. As discussed above, when the backiron components rotate, the magnetic walls (e.g. the side wall 404 andthe inner magnetic cylindrical wall 408) also rotate because the magnetsare fixedly mounted to the back iron components as described above.Thus, when the ball and knuckle assembly 602 rotates one radial magneticpole or magnetic cylindrical segment length (e.g., 45 degrees for aneight pole or eight cylindrical segment motor), the side plate 212 willalso rotate, which in turn will cause the inner cylindrical walls 211and 207 to rotate with respect to the other back iron components (e.g.the side wall 208 and the outer cylinder walls 206 and 210).

The rotation of the magnets will follow causing a rotation from a firstor NNNN configuration illustrated in FIG. 5D to a second or NNSSconfiguration as illustrated in FIG. 5G. In certain embodiments,friction between the joints of the ball and knuckle assembly 602 canmaintain a controlled rotation from the first configuration to a secondconfiguration. In yet, other embodiments, a gear system 622 may be usedin conjunction with the rotating swash plate 616 to control the rate ofrotation as illustrated in FIGS. 8D and 8E. FIG. 8D illustrates anisometric view of one embodiment of the ball and knuckle assembly 602where the rotating swash plate 616 is coupled to the gear system 622 tomechanically control the rate of rotation of the rotating swash plate.FIG. 8E is an isometric view of the gear system from another angle.

To limit the overall relative rotation, curved slots may be defined inthe swash plates or side walls 208 and 212 as illustrated by the curvedslots 620 of FIG. 1. Curved slots 620 limit the over all rotation of thepins 618 (see also FIG. 1), and hence limit the overall rotation of theball and knuckle assembly 602.

FIG. 9 is an exploded view illustrating an embodiment using two the balland knuckle assembles 602 and 603 coupled to back iron components,specifically the flat side walls 208 and 212, respectively (See FIG. 4B)and slidingly coupled to the rotor shaft 302. The embodiment illustratedin FIG. 9 is similar to the embodiments above. So, identical or similarelements will not be repeated here for reasons of clarity. In theembodiment illustrated in FIG. 9, the side walls 208 and 212 may rotateindependently of the outer cylindrical walls 206 and 210 and the innercylindrical walls 207 and 211 (not visible in FIG. 9).

In this embodiment, the ball and knuckle assemblies 602 and 603 aredesigned to rotate in unison. Consequently, the side walls 208 and 212will rotate in unison with respect to the inner side walls 207 and 211and outer side walls 206 and 210. (As before, the inner side walls 207and 211 are either joined together or replaced with a single wall.Similarly, the outer side walls 206 and 210 are joined together orreplaced with a single outer wall). The embodiment illustrated in FIG. 9illustrates a NNNN configuration to NSNS configuration rotation. Referback to FIGS. 5C and 5D for a discussion of the NNNN configuration andto FIGS. 5D and FIG. 5F for a discussion of the NSNS configuration. Asdiscussed above, when the back iron components rotate, the magneticwalls (e.g. side walls 404 and 402) also rotate because the magnets arefixedly mounted to the back iron components as described above. Thus,when the ball and knuckle assembly 602 rotates through one radialmagnetic pole or magnetic cylindrical segment length (e.g., 45 degreesfor an eight pole or eight cylindrical segment motor), the side plate212 will also rotate (causing the magnetic side wall 404 or rotors torotate through the same angle). In unison, the ball and knuckle assembly603 rotates one radial segment length, the side plate 208 will alsorotate (causing the magnetic side wall 402 or rotor to rotate throughthe same angle). In certain embodiments, a coupling device may be usedto couple the rotor hub 300 to the outer cylindrical walls 206 and 210so that they will rotate in unison and independently of the side plates208 and 212 through the magnetic pole configuration transition. Therotation of the magnetic walls 402 and 404 (or rotors) will follow therotation of the back iron walls 208 and 212 causing a rotation from afirst or NNNN configuration illustrated in FIGS. 5C and 5D to a secondor NSNS configuration as illustrated in FIG. 5E and 5F.

The ball and knuckle assemblies described above are only one embodimentof a rotation actuator which may be used in the disclosed embodiments.Various other options may be used to shift or rotate the magneticconfiguration. For instance, a mechanism which uses centrifugal force tocause a weighted positioner to force the rotor plates into the newposition may also be used. As the speed of rotation becomes fast enough,the weighted positioner will be thrown from an interior position asillustrated an exterior position. The outward movement of the weightedpositioner, in turn causes the back iron components to rotate apredetermined amount. Once the speed slows, a biasing member, such as aspring, allows the weighted positioner to return to its originalposition.

In other embodiments, applying external power or energy to a pressureplate to move the back iron components relative to each other may beused. Other embodiments may use a mechanism which applies a mechanicalbraking force to rotate the back iron components relative to each other.

Another rotation actuator may use solenoids, hydraulic or pneumatic ramsto apply a force to the back iron components via either electrically ora mechanical linkage. In all cases, the appropriate back iron componentsmay be rotated into a new position relative to the other back ironcomponents to create a new magnetic configuration. The degree ofrotation may depend on the number of poles or magnetic tunnels selectedin a particular motor. For instance, a “two pole” or “two cylindricalsegment” toroidal magnetic cylinder would require a rotation of 180degrees to shift from a first configuration to a second configuration.On the other hand, a four pole would require a ninety (90) degreerotation. A six pole may require a 60 degree rotation, and so on.

In the various switching mechanisms such as the power plate, as power isapplied an equal force is transferred to both plates of the rotor and arotation is imposed. At a selected speed the pressure plate is appliedto one side of a rotor plate. This imposes a drag on the plate reducingits speed. However the speed of the other plate remains constant whichforces a shift in the plate's alignment. The shifting action continuesto occur until the stop is reached and the rotor plates settle into asecond configuration. Since the transition duration is a relatively sortinterval it is also possible that power can simply be shut off while thetransition takes place.

Upon deceleration the opposite action takes place. Again at apreselected speed the pressure plate is applied, which shifts the backiron walls back into a first configuration. This shifting occurs becausethe motor is acting as a generator putting a drag on the plates. Areturn spring may also be utilized to aid the transition back to thefirst configuration. Throughout the switching, the coils may only beallowed to “fire” at pre programmed times to insure the appropriatecoils are producing power at the appropriate times. In variousembodiments, the coils may also be used as an aid in the switchingprocess.

In yet other embodiments, a clutch and eddy brake system may be used. Incertain embodiments, all side and cylinder walls may be connected to acommon shaft. A clutch or a decoupling mechanism may detach the selectedpair of rotors or walls. Once the two pair of rotors (e.g., magneticwalls 402 and 404 via the magnetic walls 208 and 212) are decoupled, aneddy current brake may temporarily apply braking torque to the selectedpair of rotors (or magnetic walls) to misalign or rotate the rotorsrelative to the coupled rotors. The eddy current brake may then bede-energized once the desired rotation angle has been achieved. Incertain embodiments, the misalignment angle may be decided according tothe operational speed.

By de-energizing the eddy current brake, the rotors (or magnetic walls)may be put in tandem through the clutch system and synchronizationwithin a modified magnetic configuration will be re-established. Theeddy current brake may be formed by a contactless arrangement in which asegmental disk rotor with surface coils will engage with the permanentmagnets of the rotor to create a braking torque. The reverse transitionfrom may be accomplished by reversal of the current direction in eddycurrent brake or gradual braking the second magnetic pole configuration(e.g. NSNS magnetic pole configuration) to the first magnetic poleconfiguration (e.g. NNNN magnetic pole configuration).

FIG. 10 is a conceptual drawing of the coil assembly 500 coupled to aplurality of Hall effect sensors 592 which are in electricalcommunication with a three phase power input and controller 590. Anyconventional switching arrangement may be utilized with the controller590 as is known in the art.

In the illustrative embodiment, the stator or coil assembly 500 maycomprise eight (8) uni-polarity sectors containing six (6) coils permagnetic sector. The coils may be are designed to stay continuouslyenergized throughout the 45 degrees of sector movement.

Two adjacent coils may be grouped in series or parallel depending ondesign requirements and linked to the equivalent coils in eachuni-polarity sector. For purposes of clarity only the “A” phase isillustrated. Coils are isolated in this embodiment, but delta and wyeconnection arrangements may also be utilized.

Each phase is energized with the proper polarity as it enters theuni-polarity sector. The appropriate Hall Effect sensor is thenactivated at this change in polarity sending a signal to the controller590 which energizes the proper polarity of power input to Phase A and acontinuous supply voltage is impressed on the circuit throughout thecoil movement.

When the Hall effect sensor detects the coil is entering the nextconsecutive uni-polarity sector, a change of state is initiated at whichtime the coils are again pulsed with a continuous voltage of the properpolarity.

This embodiment uses a variable voltage at the power inputs to controlspeed and torque as appropriate and may be utilized as another method tocontrol field weakening. Other Phase sequences are possible with thisarrangement. For example a 6 phase supply could be connected to 6circuit groups thus enabling a multipole high torque machine withoutphysical rearrangement of the motor supply conductors. Software canrecombine the coil pulse order to overlap adjacent coils of a particulargroup enabling a 3 phase supply.

The abstract of the disclosure is provided for the sole reason ofcomplying with the rules requiring an abstract, which will allow asearcher to quickly ascertain the subject matter of the technicaldisclosure of any patent issued from this disclosure. It is submittedwith the understanding that it will not be used to interpret or limitthe scope or meaning of the claims.

Any advantages and benefits described may not apply to all embodimentsof the invention. When the word “means” is recited in a claim element,Applicant intends for the claim element to fall under 35 USC 112(f).Often a label of one or more words precedes the word “means”. The wordor words preceding the word “means” is a label intended to easereferencing of claims elements and is not intended to convey astructural limitation. Such means-plus-function claims are intended tocover not only the structures described herein for performing thefunction and their structural equivalents, but also equivalentstructures. For example, although a nail and a screw have differentstructures, they are equivalent structures since they both perform thefunction of fastening. Claims that do not use the word means are notintended to fall under 35 USC 112(f).

The foregoing description of the embodiments of the invention has beenpresented for the purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed. Many combinations, modifications and variations are possiblein light of the above teaching. For instance, in certain embodiments,each of the above described components and features may be individuallyor sequentially combined with other components or features and still bewithin the scope of the present invention. Undescribed embodiments whichhave interchanged components are still within the scope of the presentinvention. It is intended that the scope of the invention be limited notby this detailed description, but rather by the claims.

What is claimed is:
 1. A electrical machine, comprising: an axial axis;a toroidal tunnel positioned about the axial axis, the toroidal tunneldefined by: a first rotor comprising a first plurality of permanentmagnetic poles circumferentially spaced about the axial axis, whereineach magnetic pole in the first plurality of permanent magnetic polesfaces towards an interior of the toroidal tunnel and has an oppositemagnetic polarity from its adjacent magnetic poles; a second rotorcomprising and positioned opposing the first rotor, the second rotorcomprising a second plurality of permanent magnetic polescircumferentially spaced about the axial axis, wherein each magneticpole in the second plurality of permanent magnetic poles faces towardsthe interior of the toroidal tunnel and has an opposite magneticpolarity from its adjacent magnetic poles; the toroidal tunnel adaptedto rotate from a first magnetic pole configuration where the magneticpoles are angularly aligned to produce a first level of electromagnetictorque, to a second magnetic pole configuration where the magnetic polesare angularly rotated to produce a second level of electromagnetictorque, a first rotation actuator coupled to at least one of the rotorsfor mechanically rotating a portion of the toroidal tunnel from thefirst magnetic pole configuration to the second magnetic poleconfiguration, and a coil assembly positioned within the toroidaltunnel.
 2. The electrical machine of claim 1, wherein the first rotorcomprises an outside cylindrical wall positioned about the axial axisand the second rotor comprises an inside cylindrical wall positionedabout the axial axis and positioned opposing the first cylindrical wall.3. The electrical machine of claim 1, wherein the toroidal tunnelfurther comprises: a third rotor positioned about the axial axis andpositioned axially adjacent to the first rotor and second rotor, whereinthe third rotor comprises a third plurality of permanent magnetic polescircumferentially spaced about the axial axis, wherein each magneticpole in the third plurality of permanent magnetic poles faces towardsthe interior of the toroidal tunnel and has an opposite magneticpolarity from its adjacent magnetic poles; and a fourth rotor positionedabout the axial axis and positioned axially adjacent to the first rotorand second rotor, and axially from the third rotor, wherein the fourthrotor comprises a fourth plurality of permanent magnetic polescircumferentially spaced about the axial axis, wherein each magneticpole in the fourth plurality of permanent magnetic poles faces towardsthe interior of the toroidal tunnel and has an opposite magneticpolarity from its adjacent magnetic poles.
 4. The electrical machine ofclaim 3, wherein the third rotor comprises a first side wall positionedadjacent to the outer cylindrical wall and inner cylindrical wall andthe fourth rotor comprises an opposing side wall positioned adjacent tothe outer cylindrical wall and inner cylindrical wall and axially awayfrom the first side wall.
 5. The electrical machine of claim 4, whereinin the first magnetic pole configuration, north magnetic pole polaritiesof the first plurality of permanent magnetic poles, the second pluralityof permanent magnetic poles, the third plurality of permanent magneticpoles, and the fourth plurality of permanent magnetic poles are allaxially and radially aligned to form a NNNN magnetic pole configuration.6. The electrical machine of claim 4, wherein in the second magneticpole configuration, north magnetic pole polarities of the firstplurality of permanent magnetic poles and the north magnetic polepolarities of the second plurality of permanent magnetic poles opposeeach other and are radially aligned with the south magnetic polepolarities of the third plurality of permanent magnetic poles and fourthplurality of permanent magnetic poles to form a NSNS magnetic poleconfiguration.
 7. The electrical machine of claim 6, wherein the firstrotation actuator is mechanically coupled to the third rotor such thatthe third rotor can rotate independently of the first rotor and secondrotor from the first magnetic pole configuration, through apredetermined angle of rotation, to the second magnetic poleconfiguration.
 8. The electrical machine of claim 7, further comprisinga second rotation actuator which is coupled to the fourth rotor suchthat the fourth rotor can rotate independently of the first rotor andthe second rotor from the first magnetic pole configuration, through thepredetermined angle of rotation to the second magnetic poleconfiguration.
 9. The electrical machine of claim 6, wherein the firstrotation actuator is mechanically coupled to both the third rotor andfourth rotor such that the third and fourth rotors can rotateindependently of the first rotor and second rotor from the firstmagnetic pole configuration, through the predetermined angle ofrotation, to the second magnetic pole configuration.
 10. The electricalmachine of claim 4, wherein in the second magnetic pole configuration,north magnetic pole polarities of the first plurality of permanentmagnetic poles and the north magnetic pole polarities of the thirdplurality of permanent magnetic poles are axially adjacent to each otherand oppose the south magnetic pole polarities of the second plurality ofpermanent magnetic poles and fourth plurality of permanent magneticpoles to form a NNSS magnetic pole configuration.
 11. The electricalmachine of claim 10, wherein the first rotation actuator is mechanicallycoupled to both the first rotor and third rotor such that the first andthird rotors can rotate independently of the second rotor and fourthrotor from the first magnetic pole configuration, through thepredetermined angle of rotation, to the second magnetic poleconfiguration.
 12. A method of producing electric electromotive rotationcomprising: positioning a toroidal tunnel about the axial axis, thetoroidal tunnel defined by: a first rotor comprising a first pluralityof permanent magnetic poles circumferentially spaced about the axialaxis, wherein each magnetic pole in the first plurality of permanentmagnetic poles faces towards an interior of the toroidal tunnel and hasan opposite magnetic polarity from its adjacent magnetic poles; a secondrotor comprising and positioned opposing the first rotor, the secondrotor comprising a second plurality of permanent magnetic polescircumferentially spaced about the axial axis, wherein each magneticpole in the second plurality of permanent magnetic poles faces towardsthe interior of the toroidal tunnel and has an opposite magneticpolarity from its adjacent magnetic poles; a third rotor positionedabout the axial axis and positioned axially adjacent to the first rotorand second rotor, wherein the third rotor comprises a third plurality ofpermanent magnetic poles circumferentially spaced about the axial axis,wherein each magnetic pole in the third plurality of permanent magneticpoles faces towards the interior of the toroidal tunnel and has anopposite magnetic polarity from its adjacent magnetic poles; and afourth rotor positioned about the axial axis and positioned axiallyadjacent to the first rotor and second rotor, and axially from the thirdrotor, wherein the fourth rotor comprises a fourth plurality ofpermanent magnetic poles circumferentially spaced about the axial axis,wherein each magnetic pole in the fourth plurality of permanent magneticpoles faces towards the interior of the toroidal tunnel and has anopposite magnetic polarity from its adjacent magnetic poles. applyingcurrent to a coil assembly positioned within the toroidal tunnel toapply an electromagnetic force to the rotors, and rotating at least onerotor defining the toroidal tunnel from a first magnetic poleconfiguration where the magnetic poles are angularly aligned to producea first level of electromagnetic torque, to a second magnetic poleconfiguration where the magnetic poles are angularly rotated to producea second level of electromagnetic torque.
 13. The method of claim 12,wherein in the first magnetic pole configuration, north magnetic polepolarities of the first plurality of permanent magnetic poles, thesecond plurality of permanent magnetic poles, the third plurality ofpermanent magnetic poles, and the fourth plurality of permanent magneticpoles are all axially and radially aligned to form a NNNN magnetic poleconfiguration.
 14. The method of claim 12, wherein in the secondmagnetic pole configuration, north magnetic pole polarities of the firstplurality of permanent magnetic poles and the north magnetic polepolarities of the second plurality of permanent magnetic poles opposeeach other and are radially aligned with the south magnetic polepolarities of the third plurality of permanent magnetic poles and fourthplurality of permanent magnetic poles to form a NSNS magnetic poleconfiguration.
 15. The method of claim 12, wherein in the secondmagnetic pole configuration, north magnetic pole polarities of the firstplurality of permanent magnetic poles and the north magnetic polepolarities of the third plurality of permanent magnetic poles areaxially adjacent to each other and oppose the south magnetic polepolarities of the second plurality of permanent magnetic poles andfourth plurality of permanent magnetic poles to form a NNSS magneticpole configuration.
 16. The method of claim 12, wherein the rotating atleast one rotor defining the toroidal tunnel further comprises rotatingthe third rotor independently of the first rotor and second rotor fromthe first magnetic pole configuration, through a predetermined angle ofrotation, to the second magnetic pole configuration.
 17. The method ofclaim 12, wherein the rotating at least one rotor defining the toroidaltunnel further comprises rotating the fourth rotor independently of thefirst rotor and the second rotor from the first magnetic poleconfiguration, through the predetermined angle of rotation to the secondmagnetic pole configuration.
 18. The method of claim 12, wherein therotating at least one rotor defining the toroidal tunnel furthercomprises rotating both the third rotor and fourth rotor independentlyof the first rotor and second rotor from the first magnetic poleconfiguration, through the predetermined angle of rotation, to thesecond magnetic pole configuration.
 19. The method of claim 12, whereinthe rotating at least one rotor defining the toroidal tunnel furthercomprises rotating the first rotor and third rotor independently of thesecond rotor and fourth rotor from the first magnetic poleconfiguration, through the predetermined angle of rotation, to thesecond magnetic pole configuration.